2., 5 Mm2, 4 Mm2 Or 6 Mm2 Aluminum Wires With Separate Butt Connectors, Repairing

Special tools and workshop equipment required

Wiring Harness Repair Set - Hot Air Blower :VAS1978/14A from the Wiring Harness Repair Set :VAS1978B
Wiring Harness Repair - Blower - Shrink Element :VAS1978/15A from the Wiring Harness Repair Set :VAS1978B
Wiring Harness Repair Set :VAS631001

NOTE:

Observe general notes for repairs on the vehicle electrical system. Refer to VEHICLE ELECTRICAL SYSTEM, GENERAL REPAIR INFORMATION .

For the repair there are copper repair wires with a 2.5mm² or 4 mm² or 6 mm² cross section.

There are also separate copper repair wires with a crimped on contacts available for the repair.

Procedure

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-- Install the corresponding crimp insert, crimp stamp and contact positioner for the wire cross-section with the contact cross bar as follows on the crimping tool.

-- Open the crimping tool from the :VAS631001 .

-- Remove the locking pin -1- all the way in the direction of -arrow A-.

-- Open the mount -2- in the direction of -arrow B-.

-- Insert the crimp insert -1- in the crimping tool so that the crimp insert -1- is flush with the front of the clamps.

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-- Tighten the crimp insert with the pins -2- in direction of -arrow A- and the knurled screw hand tight.

-- Insert the crimp stamp -3- that fits the crimp insert in the mount.

-- Secure the crimp stamp with the pin -4- in direction of -arrow B- and the knurled screw hand-tight.

-- Close the adapter -1- in the direction of -arrow A-.

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-- Push the locking pin -2- in the direction of -arrow- all the way.

-- Insert the contact cross bar -1- in the contact positioner -2-.

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-- Position the contact positioner with the contact cross bar on the crimping tool -5- at the same time push the holes in the contact positioner -2- over the knurled screw -4-.

-- Install the knurled bolt -3- and tighten hand-tight.

-- Free up the wire to be repaired approximately 20 cm on both sides of the repair point.

CAUTION:

Risk of damaging the electrical wires.

Expose wrapped wiring harnesses carefully.

-- If necessary, removing the wiring harness wrapping.

-- Cut the damaged section of the wire with wire stripper from the :VAS631001 .

Fig 1: Cutting Wire

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NOTE:

When both ends of the vehicle-specific single wire are too short after cutting out the damaged wire section for a repair with a separate butt connector, insert a corresponding long piece of yellow copper repair wire with two butt connectors.

-- Insert the wire end from the front all the way in to the wire cross-section corresponding mount in the jaws of the pliers.

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-- Push the pliers completely together.

-- Open pliers again and remove the stripped wire end.

The insolation must be cut cleanly and remove from the wires.
No insolation can remain on bare wires.
The single wires must not be damaged.

-- For the repair remove the corresponding butt connection with a heat-shrinkable tube from the :VAS631001 .

-- Push the heat-shrinkable tube on one of the wires.

-- Place the butt connection -1- in the contact positioner -2-.

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The butt connection -1- must be flush with the contact positioner -2- -arrow A-.

-- Push the contact cross bar -3- all the way in the direction of the -arrow B- and secure it with the butt clamp -1-.

The tab -4- on the butt connection -1- must engage in the groove -5- on the contact cross bar -3-.

-- Insert the wire -2- with the bare wire end all the way in the butt connection -1- -arrow-.

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All single wires must be pushed into the butt connection.
The insolation end can at a maximum be flush with the front edge of the insolation crimps.

-- Close the crimping tool completely until it reopens by itself.

-- Push the contact cross bar -2- all the way in the direction of -arrow-.

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-- Remove the butt connection -1- from the contact positioner -3-.

-- Turn the crimping tool for the second crimping.

-- Repeat the wire crimping on the other side as described.

-- Remove the securing pin -1- in the direction of -arrow A- until it stops.

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-- Open the mount -2- in the direction of -arrow B-.

-- Remove the crimped butt connectors.

Correct crimping results

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The wire ends must project 0.1 mm to 1.0 mm on the front edge of the wire crimps, dimension -a-
The insolation end must not be crimped in the wire crimps.
The insolation end can at a maximum be flush with the front edge of the insolation crimps -arrows-.

After crimping the heat-shrinkable tube must positioned over the butt connection and heat-shrunk with a hot air gun, to prevent moisture from entering.

Fig 2: Heating Crimp Connection Using Hot Air Gun

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-- Insert the :VAS1978/15A on the :VAS1978/14A .

CAUTION:

Risk of damaging surrounding components.

When heat-shrinking the heat-shrinkable tube, be careful not to damage any other wiring, plastic parts or insulating material with the hot nozzle of the hot air blower.
Always observe operating instructions of heat gun.

-- Position the heat-shrinkable tube -1- centered over the butt connection -2-.

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The dimension -a- must be approximately the same on both sides

-- Heat the heat-shrinkable tube using the hot air blower lengthwise from center outward until it is sealed completely and adhesive comes out the ends.

The completed repair location -3- must look like so.

NOTE:

Make sure that the butt connections do not lie directly next to each other when several wires need to be repaired. Arrange the butt connection at a slight offset so that the circumference of the wiring harness does not become too large.

Fig 3: Identifying Offset Positions Of Crimped Connections

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If the repair point was previous taped, this point must be taped again with yellow insulating tape after repairs.

Secure the repaired wiring harness if necessary with a cable tie to prevent flapping noises while driving.